Inlaid type floor sheet having polyvinyl chloride chip and the method of manufacturing thereof

ABSTRACT

Disclosed is a inlaid type floor sheet having polyvinyl chloride chip and a method of manufacturing thereof. The in-laid type floor sheet having polyvinyl chloride (PVC) chip, includes an inlaid chip layer in which polyvinyl chloride is formed into chips; a UV paint layer which is coated on the inlaid chip layer; and a dimensionally reinforcing layer which is formed of a fabric and pressed on a lower surface of the inlaid chip layer at high temperature. According to the present invention, since the plain weave type dimensionally reinforcing layer is provided at the lower side of the inlaid type floor sheet having polyvinyl chloride chip, it is possible to improve the durability, realize the dimensional stability and balance of the product and increase the adhesive force with the construction floor.

TECHNICAL FIELD

The present invention relates to an inlaid type floor sheet havingpolyvinyl chloride chip and a method of manufacturing thereof, and moreparticularly to an inlaid type floor sheet having polyvinyl chloridechip and a method of manufacturing thereof, in which a plain-weave typedimensionally reinforcing layer is provided at a lower side of theinlaid type floor sheet having polyvinyl chloride chip, therebyimproving durability, realizing dimensional stability and balance of aproduct and increasing adhesive force with a construction floor.

BACKGROUND ART

FIG. 1 is a cross-sectional view of a conventional inlaid type floorsheet having polyvinyl chloride chip (hereinafter, called ‘floorsheet’).

As shown in FIG. 1, the conventional floor sheet 10 is a non-foamingtype and includes an inside layer 11 which is adhered to a constructionfloor, a dimensionally reinforcing layer 12 which is disposed on theinside layer 11 and formed of glass fiber, a polyvinyl chloride chiplayer 13 which is disposed on the dimensionally reinforcing layer 12,and a UV curable paint layer 14 which is coated on the polyvinylchloride chip layer 13, wherein each layer is stacked in turn from alower side to an upper side of the drawing.

As described above, the floor sheet 10 has the polyvinyl chloride chiplayer 13 which provides relatively higher durability than a general PVCfloor sheet, and the polyvinyl chloride chip layer 13 functions tomaintain the surface shape of a product as much as possible, even thoughthe surface of the product is worn. Therefore, the floor sheet 10 isused in some places where high durability of the product is required dueto frequent use by many people. Meanwhile, as a thickness of thepolyvinyl chloride chip layer 13 is increased, the durability of thefloor sheet 10 is enhanced, but it is substantially limited to increasethe thickness of the polyvinyl chloride chip layer 13.

FIG. 2 shows another example of the conventional floor sheet forovercoming the above-mentioned problem.

As shown in FIG. 2, the conventional floor sheet 20 is a non-foamingtype and includes a polyvinyl chloride chip layer 21 and a UV curablepaint layer 22 which is coated on the polyvinyl chloride chip layer 21.

Meanwhile, the floor sheet 20 which includes the dimensionallyreinforcing layer 12 as shown in FIG. 1 is called ‘a Hetero homogeneoustype’, and the floor sheet 20 which includes only the polyvinyl chloridechip layer 21 as shown in FIG. 2 is called ‘a homogeneous type’.

In case of the Hetero homogeneous type floor sheet 10 shown in FIG. 1,the thickness of the polyvinyl chloride chip layer 13, which is directlyassociated with the durability of the product, is formed to be thin,i.e., about 1.25 mm, and thus it has a durability of about 10 years.However, since it has the dimensionally reinforcing layer 12, it isadvantageous to realize the dimensional stability and balance of theproduct and also it is facile to handle and construct it.

And in case of the homogeneous type floor sheet 10 shonw in FIG. 2, thepolyvinyl chloride chip layer 21 is thicker than that of the Heterohomogeneous type floor sheet 10, and thus it has a longer durability ofabout 15 years. However, its dimensional stability is low, and since thepolyvinyl chloride chip layer 21 formed of a hard material is directlycontacted with the construction floor, it is difficult to handle andconstruct it.

DISCLOSURE OF INVENTION Technical Problem

An object of the present invention is to provide an inlaid type floorsheet having polyvinyl chloride chip and a method of manufacturingthereof, in which a plain-weave type dimensionally reinforcing layer isprovided at a lower side of the inlaid type floor sheet having polyvinylchloride chip, thereby improving durability, realizing dimensionalstability and balance of a product and increasing adhesive force with aconstruction floor.

The object of the present invention is not limited to this, and otherobjects will be understood from the below description.

Solution to Problem

To achieve the object of the present invention, the present inventionprovides an inlaid type floor sheet having polyvinyl chloride (PVC)chip, including an inlaid chip layer in which polyvinyl chloride isformed into chips; a UV paint layer which is coated on the inlaid chiplayer; and a dimensionally reinforcing layer which is formed of a fabricand pressed on a lower surface of the inlaid chip layer at hightemperature.

Preferably, the dimensionally reinforcing layer is formed of a plainweave prepared through a high temperature scouring process.

Preferably, the dimensionally reinforcing layer 130 has a grid of 1×1mm.

Further, the present invention provides a method of manufacturing aninlaid type floor sheet having PVC chip, including (a) transporting adimensionally reinforcing member formed of a fabric; (b) coating PVCchips on the dimensionally reinforcing member; (c) pre-heating anintermediate molded member formed through the coating of the PVC chips;(d) pressing the intermediate molded member up and donw; and (e) coatingand curing a UV curable paint on a final molded member formed throughthe pressing of the intermediate molded member.

Preferably, the dimensionally reinforcing member is formed of a plainweave prepared through a high temperature scouring process.

Advantageous Effects of Invention

According to the inlaid type floor sheet having polyvinyl chloride chipand the method of manufacturing thereof of the present invention, sincethe plain-weave type dimensionally reinforcing layer is provided at thelower side of the inlaid type floor sheet having polyvinyl chloridechip, it is possible to improve the durability, realize the dimensionalstability and balance of the product and increase the adhesive forcewith the construction floor.

The effect of the present invention is not limited to this, and othereffects will be understood from the below description.

BRIEF DESCRIPTION OF DRAWINGS

The above and other objects, fretures and advantages of the presentinvention will becom apparaent from the following description ofpreferred embodiments given in conjunction with the accompany drawings,in which:

FIGS. 1 and 2 are cross-sectional views of a conventional floor sheet.

FIG. 3 is a cross-sectional view of an inlaid type floor sheet havingpolyvinyl chloride chip according to an embodiment of the presentinvention.

FIG. 4 is a perspective view of a dimensionally reinforcing layer in theinlaid type floor sheet having polyvinyl chloride chip according to theembodiment of the present invention.

FIG. 5 is a flow chart showing a manufacturing method of the inlaid typefloor sheet having polyvinyl chloride chip according to an embodiment ofthe present invention.

DETAILED DESCRIPTION OF MAIN ELEMENTS

100: floor sheet

110: inlaid chip layer

120: UV paint layer

130: dimensionally reinforcing layer

160: dimensionally reinforcing member

170: polyvinyl chloride chip

180: intermediate molded member

190: final molded member

BEST MODE FOR CARRYING OUT THE INVENTION

Hereinafter, the embodiments of the present invention will be describedin detail with reference to accompanying drawings.

FIG. 3 is a cross-sectional view of an inlaid type floor sheet havingpolyvinyl chloride chip according to an embodiment of the presentinvention, FIG. 4 is a perspective view of a dimensionally reinforcinglayer in the inlaid type floor sheet having polyvinyl chloride chipaccording to the embodiment of the present invention, and FIG. 5 is aflow chart showing a manufacturing method of the inlaid type floor sheethaving polyvinyl chloride chip according to an embodiment of the presentinvention.

As shown in the drawings, an inlaid type floor sheet 100 (hereinafter,called ‘floor sheet’) having polyvinyl chloride (PVC) chip according toan embodiment of the present invention incldues an inlaid chip layer 110in which PVC is formed into chips, a UV paint layer 120 which is coatedon the inlaid chip layer 110, and a dimensionally reinforcing layer 130which is attached to a lower surface of the inlaid chip layer 110.

As shown in FIG. 3, the inlaid chip layer 110 is formed by coatingirregular or regular shaped chips on the dimensionally reinforcing layer130. In the embodiment, the inlaid chip layer 110 is formed to have athickness t of 1.8 to 2.0 mm which is increased by about 50% compared tothe conventional one. The inlaid chip layer 110 has a great influence onthe durability of the floor sheet 100. In the embodimenet, thedurability of the floor sheet 100 can be remarkably increased byincreasing the thickness of the inlaid chip layer 110. According to theembodiment, the thickness t of the inlaid chip layer 110 may be equal toor larger than that of the PVC chip layer 21 in the conventionalhomogeneous type floor sheet.

The UV paint layer 120 is formed by coating a UV paint on the inlaidchip layer 110. The UV paint layer 120 functions to prevent a liquidcontaminant from be penetrated into the inlaid chip layer 110 and alsoallows surface contamination to be easily removed.

In the embodiment, as shown in FIGS. 3 and 4, the dimensionallyreinforcing layer 130 which can satisfy the dimensional stability anddurability of the floor sheet 100 is attached to the lower surface ofthe inlaid chip layer 110. The dimensionally reinforcing layer 130 isformed into a fabric type, thereby further improving adhesive force ofthe floor sheet 100 with respect to a construction floor.

Meanwhile, the dimensionally reinforcing layer 130 has a desiredelongation rate in all directions so as to prevent sliding of the floorsheet 100, and preferably, the dimensionally reinforcing layer 130 isfomred of a plain weave. For example, in case that the dimensionallyreinforcing layer 130 is a fabric formed of braid, there is a highprobability that dimensionally reinforcing layer 130 is slid on theconstruction floor.

In addition, since the plain weave type fabric has a bad effect on ashrinkage rate due to its weakness in heat, it is preferable that thedimensionally reinforcing layer 130 is formed into the plain weave typemanufactured through a high temperature scouring process. Further, asshown in FIG. 4, the dimensionally reinforcing layer 130 is formed tohave a density of 25 mesh, more detailedly a grid of 1×1 mm.

In other words, since the dimensionally reinforcing layer 130 is formedinto the plain weave type and also formed to have a density of about 25mesh, it is possible to increase the dimensional stability of the floorsheet 100 and also to improve the balance of the floor sheet 100 in alldirections. Furthermore, since the dimensionally reinforcing layer 130is formed into the plain weave type, frictional force with respect tothe construction floor is increased and thus the adhesive force of thefloor sheet 100 is also increased. Herein, the dimensional stabilitymeans a degree of dimensional change of the floor sheet 100 with respectto a preset size thereof.

Hereinafter, referring to table 1, the dimensional stability and theadhesive strength in each of the floor sheet 100 of the presentinvention and the conventional Homogeneous floor sheet 20 will becompared. Herein, in order to test the dimensional stability, a testpiece of 30 cm×30 cm is put in a dry oven of about 80° C. for 6 hoursand then the degree of the dimensional change is measured. Further, inorder to test the adhesive strength, a test piece of 25 cm×25 cm isattached to a slate plate using an aqueous acrylic adhesive and thenstretched using a tensile tester so as to measure a peel strength.

EMBODIMENT

The dimensional stability and the adhesive strength were measured usingthe floor sheet 100 in which the UV paint layer 120, the inlaid chiplayer 110 and the dimensionally reinforcing layer 130 were stacked inturn.

COMPARATIVE EXAMPLE

As shown in FIG. 2, the dimensional stability and the adhesive strengthwere measured using the floor sheet 100 in which the UV paint layer 22and the PVC chip layer 21 were stacked in turn.

TABLE 1 Comparative example (Homogeneous type) Embodiment Dimensionalstabililty (%) 0.6 0.3 Adhesive strength (Kgf) 61 82

Referring to table 1, the floor sheet 100 of the present invention hasthe lower degree of dimensional change and the higher adhesive strengththan the conventional Homogeneous type floor sheet 20.

Hereinafter, a method (hereinafter, called “a manufacturing method”) ofmanufacturing the inlaid type floor sheet having polyvinyl chloride chipaccording to the embodiment of the present invention will be described.

As shown in FIG. 5, the manufacturing method according to the presentinvention includes the steps of (a) transporting a dimensionallyreinforcing member 160 formed of a fabric; (b) coating PVC chips on thedimensionally reinforcing member 160; (c) pre-heating an intermediatemolded member 180 formed through the step (b); (d) pressing theintermediate molded member 180 up and donw; and (e) coating and curing aUV curable paint on a final molded member 190 formed through the step(d). And after the step (e), the manufacturing method further includes astep of winding the final molded member 190 passed through the step (e).

Herein, preferably, the dimensionally reinforcing member 160 is preparedthrough the high temperature scouring process in order to increase thedimensional stability and the adhesive strength.

INDUSTRIAL APPLICABILITY

As described above, since the plain-weave type dimensionally reinforcinglayer is provided at the lower side of the inlaid type floor sheethaving polyvinyl chloride chip, it is possible to improve thedurability, realize the dimensional stability and balance of the productand increase the adhesive force with the construction floor.

While the present invention has been described with respect to thespecific embodiments, it will be apparent to those skilled in the artthat various changes and modifications may be made without departingfrom the spirit and scope of the invention as defined in the followingclaims.

1. An inlaid type floor sheet having polyvinyl chloride (PVC) chip,comprising: an inlaid chip layer 110 in which polyvinyl chloride isformed into chips; a UV paint layer 120 which is coated on the inlaidchip layer 110; and a dimensionally reinforcing layer 130 which isformed of a fabric and pressed on a lower surface of the inlaid chiplayer 110 at high temperature.
 2. The inlaid type floor sheet accordingto claim 1, wherein the dimensionally reinforcing layer 130 is formed ofa plain weave prepared through a high temperature scouring process. 3.The inlaid type floor sheet according to claim 1, wherein thedimensionally reinforcing layer 130 has a grid of 1×1 mm.
 4. A method ofmanufacturing an inlaid type floor sheet having PVC chip, comprising:(a) transporting a dimensionally reinforcing member 160 formed of afabric; (b) coating PVC chips on the dimensionally reinforcing member160; (c) pre-heating an intermediate molded member 180 formed throughthe coating of the PVC chips; (d) pressing the intermediate moldedmember 180 up and donw; and (e) coating and curing a UV curable paint ona final molded member 190 formed through the pressing of theintermediate molded member
 180. 5. The method according to claim 4,wherein the dimensionally reinforcing member 160 is formed of a plainweave prepared through a high temperature scouring process.